CN-117098672-B - Sheet assembly for forming one or more cards

Abstract

The sheet assembly (100) may be cut into cards (102) including an upper layer (124) configured to receive a first print (122), a core layer (126) coupled to the upper layer and a lower layer (128) configured to receive a second print (130) and coupled to the core layer, wherein the core layer is disposed between the upper and lower sheets. One or more of the upper, core or lower layers is formed from paper impregnated with a resin, including a bio-based resin. The bio-based resin may include one or more of plants, petroleum-based or non-petroleum-based, cellulose, lignocellulose, natural fibers, starches, polysaccharides, fats and oils, proteins and/or alginates, kenaf, sisal, jute, hemp and flax, corn starch, potato starch, tapioca starch, pectin, chitin, levan, pullulan, soybean, raschig laquer, rapeseed, casein, zein, soy protein, PLA, PHA, PBAT, PBS, PE, PP, PET, PUR, EPDM, PVC, PMMA, PEF, PTF, PTT, SBR, PBT, ABS, PA, APC, CA.

Inventors

• Suvi John Sanger Karatana
• Robert Michael Colson

Assignees

• 伊利诺斯工具制品有限公司

Dates

Publication Date

20260512

Application Date

20220210

Priority Date

20210210

Claims (20)

1. 1. A sheet assembly configured to be cut into one or more cards, the sheet assembly comprising: an upper layer configured to receive a first print of one or more cards; A core layer coupled to the upper layer, and A lower layer configured to receive a second print of one or more cards, the lower layer coupled with a core layer, the core layer disposed between the upper layer and the lower layer, Wherein one or more of the upper layer, the core layer, or the lower layer is formed of paper impregnated with a resin, the resin comprising a bio-based resin, Wherein one or more of the paper or resin of one or more of the upper layer, the core layer, or the lower layer comprises high density inorganic particles comprising one or more conductive particles, wherein the inorganic particles are separated from each other by paper and/or a bio-based resin such that there is no conductive path through the sheet assembly.
2. 2. The sheet assembly of claim 1, wherein the resin further comprises a petroleum-based resin.
3. 3. The sheet assembly of claim 1 or 2, wherein the resin is a bio-based resin having 40% -70% and the remaining resin is a petroleum-based resin.
4. 4. The sheet assembly of claim 1, wherein the inorganic particles comprise one or more of bismuth vanadate, metal oxide pigments, copper particles, or bronze particles.
5. 5. The sheet assembly of claim 1 wherein the upper layer, the core layer, and the lower layer extend continuously from a first edge of the sheet assembly to an opposing second edge of the sheet assembly, and the upper layer, the core layer, and the lower layer extend continuously from a third edge of the sheet assembly to an opposing fourth edge of the sheet assembly, wherein each of the third edge and the fourth edge extend continuously from the first edge to the second edge, Wherein the sheet assembly does not conduct current from any of the first edge, the second edge, the third edge, or the fourth edge to any of the first edge, the second edge, the third edge, or the fourth edge.
6. 6. The sheet assembly of claim 1, wherein the core is formed from at least an upper core, a middle core, and a lower core, wherein the upper core is located between the middle core and the upper layer, and the lower core is located between the middle core and the lower layer, and one or both of the upper core or the lower core comprises one or more of a reflective feature, a diffractive feature, or a holographic feature.
7. 7. The sheet assembly of claim 6, further comprising an inlay disposed on the intermediate core layer between the upper core layer and the lower core layer, the inlay including a radio frequency identification antenna.
8. 8. The sheet assembly of claim 1, further comprising a bio-based upper film and a bio-based lower film.
9. 9. The sheet assembly of claim 8, wherein the upper and lower bio-based films are bio-based polycarbonate films.
10. 10. The sheet assembly of claim 8, wherein one or more of the bio-based upper film and the bio-based lower film includes a security feature.
11. 11. The sheet assembly of claim 8, wherein one or more of the bio-based upper film and the bio-based lower film comprises one or more of metallized, holographic, diffractive, refractive, or color shifting features.
12. 12. The sheet assembly of claim 1, further comprising: an upper transparent cover layer disposed over the upper layer, and A lower transparent cover layer disposed over the lower layer, wherein one or more of the upper transparent cover layer or the lower transparent cover layer is formed from a bio-based polymer or paper impregnated with a resin, the resin comprising a bio-based resin.
13. 13. A card made from the sheet assembly of any of claims 1-12, wherein the card is one or more of a financial transaction card, an identity card, a key fob, or a security card.
14. 14. A card made from the sheet assembly of any one of claims 1-12, wherein the card is an access card.
15. 15. A sheet comprising the sheet assembly of any one of claims 1-12, wherein the sheet forms one or more of a counter, a counter top, a furniture covering, or a floor.
16. 16. A method for forming a sheet assembly, comprising: Forming a core layer; coupling an upper layer to the core layer, the upper layer configured to receive a first print of one or more cards, and Coupling a lower layer to the core layer to form a sheet assembly consisting of the upper layer, the core layer, and the lower layer, the lower layer coupled to the core layer, wherein the core layer is disposed between the upper layer and the lower layer, the lower layer configured to receive a second print of the one or more cards, Wherein the sheet assembly is configured to be cut into one or more cards, Wherein one or more of the upper layer, the core layer, or the lower layer is formed of paper impregnated with a resin, the resin comprising a bio-based resin, Wherein one or more of the paper or resin of one or more of the upper layer, the core layer, or the lower layer comprises high density inorganic particles comprising one or more conductive particles, wherein the inorganic particles are separated from each other by paper and/or a bio-based resin such that there is no conductive path through the sheet assembly.
17. 17. The method of claim 16, wherein the resin further comprises a petroleum-based resin.
18. 18. The method of claim 16 or 17, wherein the resin is 40% -70% bio-based resin and the remaining resin is petroleum-based resin.
19. 19. The method of claim 16, wherein the inorganic particles comprise one or more of bismuth vanadate, metal oxide pigments, copper particles, or bronze particles.
20. 20. The method of claim 16 wherein the upper layer, the core layer, and the lower layer extend continuously from a first edge of the sheet assembly to an opposing second edge of the sheet assembly, and the upper layer, the core layer, and the lower layer extend continuously from a third edge of the sheet assembly to an opposing fourth edge of the sheet assembly, wherein each of the third edge and the fourth edge extend continuously from the first edge to the second edge, Wherein the sheet assembly does not conduct current from any of the first edge, the second edge, the third edge, or the fourth edge to any of the first edge, the second edge, the third edge, or the fourth edge.

Description

Sheet assembly for forming one or more cards Cross-reference to related applications The present application claims priority from U.S. application 63/147,898 filed on 10, 2, 2021, the entire contents of which are incorporated herein by reference. Technical Field The subject matter described herein relates to a multi-layer sheet assembly that can be cut into smaller cards, such as identification cards, financial transaction cards (credit cards, debit cards, gift cards, etc.), or other types of cards. Background Cards may be used for a variety of purposes such as identification or security, financial transactions, etc. With increasing environmental concerns and the trend toward "green" products, some manufacturers turn to producing biodegradable cards. These cards are formed from a plurality of paper layers held together by biodegradable polymers. These known degradable cards are not durable and may not withstand repeated use, humid environments, etc. For example, some such cards are subject to flaking, which makes the card unusable. Some higher end financial transaction cards are made of or include metal to provide heavier cards, which may be desirable to consumers. The introduction of these types of materials may make recycling of the card more difficult or costly. Disclosure of Invention In one embodiment, a sheet assembly capable of being cut into one or more cards is provided. The sheet assembly includes an upper layer configured to receive a first print of one or more cards. The sheet assembly may also include a core layer coupled with the upper layer and the lower layer, the lower layer configured to receive a second print of one or more cards. The lower layer may be coupled to a core layer disposed between the upper and lower sheets. One or more of the upper, core, or lower layers may be formed of paper impregnated with a resin, including a bio-based resin. In one embodiment, a method for producing a sheet assembly may include forming a core layer and coupling an upper layer to the core layer, the upper layer configured to receive a first print of one or more cards. The method may include coupling a lower layer to a core layer to form a sheet assembly including an upper layer, a core layer, and a lower layer. The lower layer may be coupled to a core layer disposed between the upper and lower layers. The lower layer may be configured to receive a second print of one or more cards. The sheet assembly may be configured to be cut into one or more cards. One or more of the upper, core, or lower layers may be formed of paper impregnated with a resin, including a bio-based resin. Brief Description of Drawings The inventive subject matter may be understood by reading the following description of non-limiting embodiments with reference to the accompanying drawings, in which: FIG. 1 illustrates a perspective view of one embodiment of a multiwall sheet assembly; FIG. 2 illustrates a cross-sectional view of the card shown in FIG. 1 taken along section line 2-2 in FIG. 1, in accordance with one embodiment; FIG. 3 illustrates a cross-sectional view of the card shown in FIG. 1 taken along section line 2-2 in FIG. 1, in accordance with one embodiment; FIG. 4 illustrates a cross-sectional view of the card shown in FIG. 1 taken along section line 2-2 of FIG. 1, in accordance with one embodiment; FIG. 5 illustrates a cross-sectional view of the card shown in FIG. 1 taken along section line 2-2 of FIG. 1, in accordance with one embodiment; FIG. 6 shows an exploded view of a card according to one embodiment, and Fig. 7 shows a flowchart of a method for forming a sheet assembly that can be cut into smaller cards, according to one embodiment. Detailed Description The subject matter of the present invention described herein provides a multiwall sheet assembly from which a number of cards can be cut. The card may be shaped to function as an identity card, security card, financial transaction card, or the like. The sheet assembly may be formed from a material comprising paper impregnated with resin. The resin may be a petroleum-based resin or a bio-based resin. The bio-based resin may include resins composed of renewable or biological resources (e.g., plants). The bio-based resin may include a non-petroleum-based resin. The resin may be thermoplastic or thermosetting. The cards may include high density particles to enhance the characteristics of the card and to provide the card with a metallic weight and metallic feel or heavy impact. High density particles may be provided to render the card non-conductive so that the card does not experience electrostatic discharge. Cards may be manufactured using current equipment for producing plastic cards. Cards may be more durable than current plastic cards and may be used for up to five years or more. The card may be, for example, a financial transaction card, an identification card, a key fob, a door access card, or a security card. The sheet assembly may also be used to form other pro